Method of manufacturing a contamination control sheet

Abstract

The present invention related to a method of manufacturing of a contamination control sheet, the method comprising the steps of: passing a web of support material from a supply roller to a coating station, and applying a coating of polymeric material to one surface of the support material; passing the coated support material through an oven to cure the polymeric material; and passing the coated support material around a cooling roller to a take up roller; characterised in that a nip roller is provided adjacent to the cooling roller so that the coated surface of the support material is pressed onto the cooling roller by the nip roller, and further characterised in that the cooling roller has a surface roughness of 0.2 to 1 Ra.

The invention claimed is: 
     
       1. A method of manufacturing of a contamination control sheet, the method comprising the steps of:
 passing a web of support material from a supply roller to a coating station, and applying a coating of polymeric material to one surface of the support material; 
 passing the coated support material through an oven to cure the polymeric material; and 
 passing the coated support material around a cooling roller to a take up roller; 
 characterised in that a nip roller is provided adjacent to the cooling roller so that the coated surface of the support material is pressed onto the cooling roller by the nip roller, and further characterised in that the cooling roller has a surface roughness of 0.2 to 1 microns Ra, and 
 wherein the cooling roller is sized to give the coated support material no less than 2 minutes of contact time on the cooling roller. 
 
     
     
       2. The method according to  claim 1 , wherein the cooling roller has a surface roughness of 0.3 to 0.6 microns Ra. 
     
     
       3. The method according to  claim 2 , wherein the cooling roller has a surface roughness of about 0.4 microns Ra. 
     
     
       4. The method according to  claim 1 , wherein the support material comprises a glass fibre reinforced polymer. 
     
     
       5. The method according to  claim 1 , wherein after the coated support material leaves the oven, the first roller it contacts is either the nip roller or the cooling roller. 
     
     
       6. The method according to  claim 5 , wherein after the coated support material leaves the oven, the coated support material first passes over the nip roller, and then passes between the nip roller and the cooling roller. 
     
     
       7. The method according to  claim 1 , wherein the nip roller is biased against the cooling roller with a force of 20 to 80 Newtons/mm. 
     
     
       8. The method according to  claim 7 , wherein the nip roller is biased against the cooling roller with a force of 40 to 60 Newtons/mm. 
     
     
       9. The method according to  claim 8 , wherein the nip roller is biased against the cooling roller with a force of about 50 Newtons/mm. 
     
     
       10. The method according to  claim 1 , wherein the cooling roller is maintained at a temperature of 15 to 25° C. 
     
     
       11. The method according to  claim 10 , wherein the cooling roller is maintained at a temperature of about 20° C. 
     
     
       12. The method according to  claim 1 , wherein the cooling roller has a diameter of 600 to 1000 mm. 
     
     
       13. The method according to  claim 12 , wherein the cooling roller has a diameter of 700 to 900 mm. 
     
     
       14. The method according to  claim 1 , wherein the cooling roller is sized to give the coated support material 2-4 minutes contact time on the roller.